Art of bonding metal to insulation



June 4, 1940. w. OSENBERG ART OF BONDING METAL TO INSULATION Filed Nov. 11, 1937 2 Sheets-Sheet 1 iii:

I W WE INVENTOR M a; 6 Y l m r m a; J

w. OSENBERG 2,203,099

ART OF BONDING METAL 1'0 INSULATION Filed Nov. 11, 1937 2 Sheets-Sheet 2 TE I 8 mmm NV E NTO R Werner Oaenbey ATTORNEYS was UNETED STTE PATENT Application November 11, 1937, Serial No. 1741;

5 Claims.

Difficulties are encountered in the attaclunent oi the conductors of electrical outlets of various types upon their respective carriers, usually of ceramic material or the like. On the one hand is the requirement that the conducting part oi metal shall have a secure mount upon the car= rier, while on the other the material of which the carrier is constructed will not stand any con sicierable pressure or the like such for instance as is encountered in screwing two parts together. The cementing oi the conducting parts provided with suitable projections 01' the like lodges, in corresponding cavities or depressions in the carrier is also not especially effective since a secure permanent mount cannot he depended on.

In the case of conducting bodies which consist of relatively massive metal oieces, as to: in stance in the case of prongs of electric contact plugs, a projection upon the conducting relatively massive body may be softened by electrl cal heating with the aid of electrodes and the softened part may be introduced into openings in ceramic carrier in order thereby to clotain a secure connection between the two parts without the application of appreciable pressure.

This method. is not applicable where the conducting parts are of sheet metal especially of sheet metal as is frequently the case in electrical outlets. in order to attain a satisfactory and secure connection in this case, without the application of appreciable pressure, it is a feature of the invention that the conducting parts which are or" sheet metal, be equipped with specie tongues which protrucle through openings in the hon-conducting wrrier, whereby the attachment is efiectecl by subjecting the protruding encl sending, upsetting, riveting or the like. 'l

this manner the fastening means may be produced as a part of the otherwise finished con ducting element, in that the tongues are stampeci out of the sheet metal or are cut out as projec tlons thereof, whereby without the application of appreciable pressure the ends protruding through the openings in the ceramic carrier may then. be bent over or riveted together without the application of appreciable pressure, since we are here concerned with sheet in particular all pressure may he avoiclecl with the use of carriers or" ceramic material or the like, where the projecting ends of the sheet metal tongues are formed into rivet "needs by electri cally heating by means or" electrodes.

The invention may be carried out in any o'i numerous embodiments. the accompanyl'ag Fig. 3. shows a front elevation. oi a simple ensbodliment of metal element in sheet form,

Fig. la is a plan view thereof,

2 is a front ovation. of a modification thereof,

Fig. 2c is'a plan. view Fig. 3 is a modification in cylindrical.- lore-1, Fig. 3c. is a plan View tiers Fig. 4 is a. modification of cylindrical form, Fi to is a plan view of the sitter,

Fig. 5 is a plan View of the modification a33- plied to a strip oi mateztal;

Fig. 5a is a sicle elevation. th

Figs. 5 and 6a respectiv l3? are modiflcatic of embodiments of Figs. 5 ant" 7 is a plan oi"- ow the tongues shown in Figs. 3 a

Fig. 8 is a modification than V 9 is a sid View of a modification of embodiment of l,

Fig. 9a is a top view ther Fig. is is a side elevation showhig the at tachmeut oi the embodiment of Fig. 9 to an insuiating carrier,

ii is a modification of the embodiment of Fig. 1&3,

Fig. 12 is a side elevation indicating the mode oi assembly of parts oi iii 9.215.

Fig. 13 shows a further modification with two projections on the conducting hotly,

Fig. 1% is a View in'longi-tuclinal cross-section showing the aopllcation of the invention to a lamp socket,

Fig. lilo is a plan view thereof partly broken away,

Fig. 15 shows the illustrative application of the metallic tongue to carrier with a metal coat 22. as illustsates applies of applying a part to are ill vention for connection of a metal part to both an insulating and another metalpart,

Fig. 21 illustrates the assembly of the metal part to the carrier by means of a hool; conformation on the former,

Fig. 22 is a View. in longitudinal cross-section showing another mode of attachment or a U- shaped metal body to a carrier,

This. 22a is a plan view there-oi,

Fig. 22h is amend view thereoi,

Fig. 23 is a View in longitudinal cross-section illustrating another application of the invention to a lamp socket,

Fig. 23a is a plan view thereof.

in Fig. l a inetal loody i in the form of a sheet or plate which is formed with alug 2. This lug 2 is inserted through a corresponding opening in a supporting body to which part I] is to he attached and in such manner that it projects through the supporting body.

Electrodes serve to convey current through the part and lug 2. Since lug 2 has a cross-section materially less than that ol part i it will be heated greatly, so that it may be shaped under small pressure exerted by the electrodes. In this shaping the projecting part of the lug 2 is de slrahly formed into a rivet head. Where we are concerned with the attachment of the metal parts to insulating loodles, secure attachment of the metal parts to the insulating loody may he attalned in this manner. The rectangular form of the lug 2 afiords assurance against turning of such lug within the opening. Since the shape is attained without the exercise of appreciable pressure, injury to the insulating loody is avoided. We is especially of value wherethe insulating hody consists of ceramic oar-correspondingly brittie material.

in Fig. 2 is shown a metal part provided with two lugs 2 which may he introduced through corresponding openings in the insulating body for purposes oi'attachment.

In Fig. 3 a cylindrical metal part is shown, winch likewise has 2. lug 2 and which protrudes through the insulating hody and is shaped thereagainot.

-1 shows a cylindrical metal part which has iour such lugs 2. A structure such as shown in Figs. 3 and 4 is especially advantageous where the attachment of cylindrical lamp sockets is inin Fig. .7) the tongue 2 is formed by stamping out and heading over at the side of the strip of material. I

In Fig. d the securing tongue 2 is formed by stamping out of the middle of the metal strip Fig. 59 shows a metal cart l on the face of which two contiguous fastening tongues 2 are disposed.

in Fig. ill is shown in dash lines how the fastening tongue 2 is secured and may be shaped into a rivet head 9.

In Fig. ii is shown the attachment of a metal part like that of Fig. 9 to an insulating body l3. in, this case the contiguous securing tongues 2 are bent over in opposite directions 'and the protruding parts of each of said lugs is formed into an independent rivet head 9.

The electrode ll which holds the work must be formed as shown in Fig. 12. That is it must ening of the lugs.

aaoaooo gage the metal part ill from opposite sides in the manner of a pair of tongs; The electrode for to no; the rivet head is suitably formed of concave shape.

Fig. 13 shows an electrode it which embraces a metal part it which is caused to protrude by means of its lugs 2 through corresponding apertures in an insulating body 8. The shaping of the lugs 2 is eilfected in this case by the aid of a roller form of electrode 33 which in itself is known.

Attachment of a socket l5 to an insulating body 8 is indicated in Fig. 1d. The cylindrical part of the socket is in this case equipped with lugs prolteierring now to the drawings there is shown truding through openings in the insulating body, which lugs are transformed into rivet heads and thereby efiect a secure mounting of the part it? to the insulating body 8.

in Fig. 115 the attachment of a sheet metal contact G6 to an insulating body 8 is shown. This embodiment is particularly useful for a trimmer condenser to effect final tuning adjustment in a radio receiver, in which the insulating body 8 will he covered with a thin covering id of metal and the capacitance would depend upon the position of sheet metal contact 06 with respect to said thin covering. An attachment tongue is bent out of the metal piece and is inserted through the opening in the insulating body and conformed as a rivet head.

in Fig. 16 there is shown in similar manner the attachment of a metal part it to an insulating body 8 with the use of two attachment tongues bent out of the metal part ill. The metal part I In to be secured may be of any suitable form. Fig. l? for instance, a ill-shaped mounting piece 08 is shownirom the metal part of which an attachment tongue may be bent out which projects' through an opening in an insulating body 8 and is shaped at its protruding end into a rivet head 2i are applied in the manner shown in Fig. 18.,

By virtue of the temperatures attained due to the heating of the electrodes, the bent over layers or parts become welded together.

Fig. 19 shows the attachment of a metal part 22 bent into a U-form and which by virtue of its U-iormcannot be introduced through a hole or aperture. in this case the aperture 23 is formed in the manner of a slot through. the side of the insulating body and the part 22 is laterally slid into said slot until it abutsat the end thereof. The material for shaping and securing of the metal part to the insulating body is afforded by lugs 2 which by shaping are pressed into flat heads :13.

Within the scope of the invention it is also possible to attach with respect to the insulating body a {piece in addition to the metal body in the shap- Fig. 2o for instance shows the projection of a lug of metal part 25 through a slot in the insulating body and also shows a distinct metal part 265 through which said lug extends, the protruding end' of the latter being formed as a rivet head In this manner three distinct bodies are simultaneously securely connected together.

-In 21 the lug on the metal part 21 is not shaped as a rivet head but bent over in the form of a hook. It thereby embraces a wire 28 and presses the latter ifightly against the insulating trudes through a slot through the insulating body 8 and the metal body 29 and is secured to the insulating body 8 illustratively by riveting over.

In similar manner Fig. 23 shows an attachment of metal parts 3| and 32 to the insulating body 8 and insulating washer 33 being inter:

posed between the two metal parts 3| and 32.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. The method of fastening a flexible sheet metal piece to a ceramic carrier, which consists in inserting snugly into and through acorresponding slot in the carrier, a tongue of reduced width stamped from the body of said metal piece' rial, extending the latter at right angles to said material, snugly through a corresponding .hole in the carrier to protrude therebeyond and causing said tongue to be softened and shaped by compression thereof to conform the end thereof into a rivet head by the application of shaped electrodes respectively to the end of said tongue and to the face of said material.

3. The method of mounting electric lamp terminals in a ceramic holder therefor which consists in superposing an insulating washer upon the cylindrical screw shell socket within the ceramic holder, superposing the central contact bar over the washer, bending the end thereof .to extend through said washer and snugly through a corresponding aperture in the ceramic holder and applying electrodes to the extremity of said end and to the face of said contact bar to cause said end to heat andsoften and to cause the protruding extremity thereof to be shaped into a rivet head under the pressure exerted by said electrodes.

4. The method of fastening the base of a U- shaped metal mounting piece to the face of a ceramic carrier, which consists in superposing a sheet metal piece over said base, bending the end thereof to extend snugly through corresponding slots in the carrier and in said base of the mounting piece and applying electrodes to the protruding extremity of said end and to another part of the sheet metal piece respectively, to cause said protruding extremity of said metal piece to be shaped into a rivet head under the pressure exerted by said electrodes.

5. The method of fastening the base of a U- shaped metal mounting piece to the face of a ceramic carrier, which consists in stamping out of said base a tongue extending at right angles 1 thereto; inserting the tongue through a corresponding slot in the carrier and applying electrodes to the end'of the protruding length of the tongue and to another part of said carrier piece respectively and thereby heating and softening the said tongue and bending, upsetting or converting into a rivet head the protruding length of said tongue.

W. OSENBERG. 

